GLP/GDP40VX5, GLP/GDP40VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50VX, GLP/GDP55VX (G813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM 4.3L)...................................................................................... LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... POWERSHIFT TRANSMISSION REPAIR...................................................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ MAIN CONTROL VALVE (WITH VARIABLE DISPLACEMENT PUMP)....................... CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................
PART NUMBER
YRM NUMBER
REV DATE
524262274 524306203 524265337 524223757 524262275 550043871 524223762 550043436 524262277 524262278 524223764 524262279 524223766 550073240 524223767 550031265
0100 YRM 1243 0100 YRM 1290 0600 YRM 1251 0700 YRM 1123 0900 YRM 1242 0900 YRM 1556 1300 YRM 1129 1300 YRM 1529 1400 YRM 1245 1400 YRM 1246 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2000 YRM 1457
05/14 04/14 05/14 03/13 08/12 04/14 09/09 08/13 01/12 12/13 07/13 03/13 04/14 12/14 04/14 01/14
524223768 524208014 524223769 524223770 524223771 524223772
2100 YRM 1139 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142
02/14 05/14 12/14 12/14 12/14 04/14
524265342 524150797 524223780 524262298 524262281 524329117 550001092 524221866
4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1248 8000 YRM 1249 8000 YRM 1387 8000 YRM 1409 9000 YRM 1112
02/14 10/13 12/14 04/13 08/11 04/14 04/14 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 524329179 (12/14)
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •
•
• • • • • • • • • • • •
•
The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:
WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS General ..................................................................................................................................................................... 1 Description ................................................................................................................................................................2 Hood, Seat, and Side Covers Replacement ............................................................................................................. 4 Remove ................................................................................................................................................................ 4 Install .................................................................................................................................................................... 4 Steering Column ..................................................................................................................................................... 12 Description ..........................................................................................................................................................12 Steering Column Repair ..................................................................................................................................... 12 Remove ..........................................................................................................................................................12 Disassemble ...................................................................................................................................................13 Clean ..............................................................................................................................................................16 Inspect ............................................................................................................................................................16 Assemble ....................................................................................................................................................... 16 Install ..............................................................................................................................................................16 LPG Tank and Bracket Replacement ..................................................................................................................... 17 Counterweight Replacement .................................................................................................................................. 17 Remove .............................................................................................................................................................. 17 Install .................................................................................................................................................................. 20 Tow Pin ...............................................................................................................................................................24 Remove and Install For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)................ 24 Remove and Install For Lift Truck Models GLC55SVX (GC/GLC80XVBCS, GC/ GLC100VXBCS; GC/GLC120SVX; and GC/GLC120VXPRS) (E818, F818) and GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (J813)......................................................................................................... 24 Overhead Guard Replacement ...............................................................................................................................25 Remove .............................................................................................................................................................. 25 Install .................................................................................................................................................................. 25 LED Tail, Backup, and Brake Lights, Replace ....................................................................................................26 Operator Restraint System Replacement ............................................................................................................... 26 Description ..........................................................................................................................................................26 Engine Replacement .............................................................................................................................................. 28 Remove Engine Only ..........................................................................................................................................28 Install Engine only .............................................................................................................................................. 56 Remove Engine and Transmission .....................................................................................................................60 Install Engine and Transmission .........................................................................................................................65 Electronic Throttle Replacement .............................................................................................................................69 Cummins 4.5L Diesel Engine With Electronic Throttle ....................................................................................... 69 Remove ..........................................................................................................................................................69 Install ..............................................................................................................................................................69 Pull Actuator Linkage Adjustment .................................................................................................................. 74 Low Idle Adjustment .......................................................................................................................................75 Throttle Pedal and Cable Adjustment ..................................................................................................................... 75 Cummins 4.5L Diesel Engine with Basic Power Shift Transmission .................................................................. 75 Kubota 3.6L Diesel Engine ................................................................................................................................. 75 Exhaust System Repair .......................................................................................................................................... 78 GM 4.3L Engine for Lift Truck Models and GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)..................................78 Cummins 4.5L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813)..................................78
©2014 Yale Materials Handling Corp.
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Table of Contents
TABLE OF CONTENTS (Continued) Remove ..........................................................................................................................................................78 Inspect ............................................................................................................................................................78 Install ..............................................................................................................................................................78 Cummins QSB 3.3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)................................. 80 Remove ..........................................................................................................................................................80 Inspect ............................................................................................................................................................82 Install ..............................................................................................................................................................82 Kubota Diesel Engine for Lift Truck Models and Equipped with Kubota 3.6L Diesel Engine GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813).............................................................................................................82 Remove ..........................................................................................................................................................82 Inspect ............................................................................................................................................................84 Install ..............................................................................................................................................................84 Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813).......................................... 84 Remove ..........................................................................................................................................................84 Inspect ............................................................................................................................................................87 Diesel Particulate Filter .................................................................................................................................. 89 Disassemble .............................................................................................................................................. 89 CLEAN AND INSPECT ..............................................................................................................................90 Assembly ................................................................................................................................................... 91 Install ..............................................................................................................................................................91 Cooling System .......................................................................................................................................................92 Description ..........................................................................................................................................................92 Hydraulic Filter Assembly Repair ............................................................................................................................93 Remove .............................................................................................................................................................. 93 Disassemble ....................................................................................................................................................... 93 Clean .................................................................................................................................................................. 94 Inspect ................................................................................................................................................................ 94 Assemble ............................................................................................................................................................94 Install .................................................................................................................................................................. 94 Fuel and Hydraulic Tanks Repair ........................................................................................................................... 94 Inspect ................................................................................................................................................................ 94 Clean .................................................................................................................................................................. 95 Steam Method of Cleaning .............................................................................................................................95 Chemical Solution Method of Cleaning .......................................................................................................... 96 Additional Preparations for Repair ......................................................................................................................96 Small Leaks, Repair ........................................................................................................................................... 96 Large Leaks, Repair ........................................................................................................................................... 96 Preparations for Use After Repair ...................................................................................................................... 96 Safety Labels .......................................................................................................................................................... 97 This section is for the following models: GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813]
ii
0100 YRM 1243
General
General WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •
•
Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.
The surface must be solid, even, and level when the lift truck is put on blocks. Make sure any blocks used to support the lift truck are solid, one-piece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck.
If additional engine repairs are necessary for lift trucks covered in this manual see: •
GM 4.3L V-6 Engines 0600YRM1251
•
Kubota Diesel 3.8L Engines 0600YRM1557
•
Kubota Diesel 3.6L Engine 0600YRM1579
If additional transmission repairs are necessary for lift trucks covered in this manual see: •
Powershift Transmission 1300YRM1129
•
Powershift Transmission 1300YRM1529
•
One and Two Speed Transmissions 1300YRM1569
This section contains the description of the frame (see Figure 1 or Figure 2) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine and transmission, and exhaust system are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.
1
Description
0100 YRM 1243
Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1 or Figure 2. There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights. See Table 2.
The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the frame with hinges. Two gas-controlled springs provide assistance when raising the hood and hold the hood in the open position. The floor plate and side covers can be removed for access to the engine, transmission, and other components.
The muffler is fastened to the frame inside the counterweight.
1. COWL PLATE 2. FENDERS 3. HOOD MOUNTS
4. COUNTERWEIGHT MOUNTS 5. HYDRAULIC TANK 6. FUEL TANK (GAS OR DIESEL) Figure 1. Frame for Lift Trucks with Single Hydraulic Tank
2
0100 YRM 1243
1. COWL PLATE 2. FENDERS 3. HOOD MOUNTS
Description
4. COUNTERWEIGHT MOUNTS 5. HYDRAULIC TANKS Figure 2. Frame for Lift Trucks with Dual Hydraulic Tanks
3
Hood, Seat, and Side Covers Replacement
0100 YRM 1243
Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat to the closest position to steering column. 2. Fully tilt steering column forward. 3. If your truck is equipped with an LPG tank, swing tank off to the side. 4. Raise latch on the left, front corner of hood to unlatch and lift up hood. See Figure 3. 5. Remove floor mat and floor plate. See Figure 4. 6. Remove two capscrews holding left and right rear side covers to the frame. Remove rear side covers from frame. See Figure 4. 7. Remove two capscrews holding left and right fender covers to front overhead guard leg. Remove covers. See Figure 4. 8. Remove four capscrews holding left and right front side covers to frame. Remove covers. 9. Fully lower the steering column. 10. Remove upper steering column cover by pulling up on upper steering column cover to release latches (one on either side), and pulling cover away from steering column. See Figure 5. 11. Remove five fasteners (see Figure 5) securing dash to the top of cowl. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash. 12. Lift kick panel to remove it from truck. See Figure 4. 13. Remove three capscrews holding the seal plate. Remove seal plate. See Figure 6. 14. Disconnect seat wire harness connector. See Figure 3.
4
CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews. Damage can be caused to the threads on the screws and in the holes. 15. If seat is to be removed, and truck is equipped with a non-swivel seat, remove seat wire harness from seat wire harness brackets that are attached to the underside of hood. Remove the cable clips from the seat wire harness. If truck is equipped with a swivel seat, remove seat wire harness from seat wire harness bracket attached to underside of hood and behind the seat. See Figure 3. 16. Remove four capscrews and washers holding seat to the hood. Lift seat off the hood. Pull seat wire harness through hood. See Figure 3. 17. Remove capscrews and washers at top of the gas springs. Remove gas springs from hood. 18. Remove hinge screws, located in the rear of the hood. 19. Lift hood from the truck. See Figure 3.
INSTALL 1. Place hood onto the lift truck frame. 2. Install hinge screws, located in the rear of the hood, and tighten to 38 N•m (28 lbf ft). See Figure 3. 3. Align top holes in the gas springs with holes in hood. There are two sets of holes used to install the gas springs to hood, based on the type of seat installed on lift truck. One set is for installing the cylinder end of the gas springs and the other set is for attaching the rod end of the gas springs. Install capscrews and washers to attach gas springs to the hood. Refer to Figure 7 and Table 1 for correct holes used to connect the rod end of the cylinder, depending on the type of seat installed on the lift truck. Tighten capscrews to 19.2 N•m (170 lbf in).
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0100 YRM 1243
Hood, Seat, and Side Covers Replacement
NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES. A. SIDE VIEW OF HOOD AND SEAT B. SIDE VIEW OF HOOD
C. BOTTOM VIEW OF HOOD D. SIDE VIEW OF VENTED HOOD WITH SWIVEL SEAT
1. 2. 3. 4. 5. 6. 7. 8. 9.
10. 11. 12. 13.
SEAT HOOD FRAME SEAT WIRE HARNESS SEAT WIRE HARNESS CONNECTOR CABLE CLIPS HINGE SCREWS GAS SPRING ATTACHMENT HOLES ATTACHING HOOD TO SEAT (SEMI-SUSPENSION)
SEAT WIRE HARNESS BRACKETS SEAT LINER HOOD LATCH ATTACHMENT HOLES ATTACHING HOOD TO SEAT (NON-SUSPENSION) 14. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (FULL SUSPENSION) 15. SPACER 16. FLANGE NUT
Figure 3. Hood and Seat Arrangement
5
Hood, Seat, and Side Covers Replacement
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
UPPER STEERING COLUMN COVER LOWER STEERING COLUMN COVER CAPSCREW DASH ASSEMBLY INSERT SCREW CLIP SEAL GROMMET KICK PANEL LEFT REAR SIDE COVER SEAL PLATE ASSEMBLY FLOOR MAT FLOOR PLATE CLIP NUT FOLDOVER NUT LEFT FENDER COVER LEFT FRONT SIDE COVER
0100 YRM 1243
19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
LEFT PANEL LEFT STEP PLATE LOCK NUT RIGHT FRONT SIDE COVER RIGHT FENDER COVER RIGHT STEP PLATE RIGHT PANEL RIGHT REAR SIDE COVER SPLASH SHIELD RADIATOR COVER GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/ GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818, F818) 29. RADIATOR COVER (GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)
Figure 4. Side Covers, Floor Plate, and Cowl Components 6
0100 YRM 1243
Hood, Seat, and Side Covers Replacement
NOTE: TOP VIEW OF DASH SHOWN. A. INDICATES TO PULL UP TO UNLATCH 1. ALLEN SCREWS 2. COWL
3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER Figure 5. Remove Dash From Cowl
7
Hood, Seat, and Side Covers Replacement
1. CAPSCREWS
0100 YRM 1243
2. SEAL PLATE Figure 6. Remove Seal Plate From Dash
8
0100 YRM 1243
Hood, Seat, and Side Covers Replacement
Figure 7. Gas Spring Installation
9